Cutting machinery

ABSTRACT

A cutting system including a cutting table and a first cutting material belt movably supported about the cutting table and a second cutting material removably supported above the first cutting material, the laser cutting material having a metal material having a plurality of apertures extending therethrough.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional application No.62/249,322 filed Nov. 1, 2015 entitled Cutting Machinery and is also acontinuation-in-part of PCT application No. PCT/US2015/017704 filed Feb.26, 2015 entitled Cutting Machinery which claims the benefit ofprovisional application No. 61/945,031 filed Feb. 26, 2014 entitledCutting Machinery and provisional application No. 62/064,841 filed Oct.16, 2014 entitled Cutting Machinery. All of the applications identifiedin this paragraph are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present application relates generally to the field of cutting asheet or roll with a blade and cutting a sheet with a laser.

SUMMARY

In one embodiment a cutting system includes a cutting table and a firstcutting material belt movably supported about the cutting table. Asecond cutting material is removably supported above the first cuttingmaterial. The laser cutting material includes a metal material having aplurality of apertures extending therethrough.

In one embodiment a cutting system includes a cutting table and a lasercutting material formed of a metal material having a plurality ofapertures extending therein.

In one embodiment a laser cutting material includes a metal materialoperatively adhered to a carrier material, the metal material having aplurality of apertures formed therein and a plurality of disks beinglocated directly below a respective aperture.

A process for forming a laser cutting material comprising securing analuminum foil to a carrier material and creating apertures into thealuminum foil.

In one embodiment a cutting material includes a plurality of panels witheach panel including a base layer and an aluminum layer secured to thebase layer. Each panel being secured to an adjacent panel with aconnector.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingfigures, wherein like reference numerals refer to like elements inwhich:

FIG. 1 is a top isometric view of a cutting system with a surfaceloader.

FIG. 2 is a top isometric view of the cutting system of FIG. 1 with thesurface loader in a second engaged position.

FIG. 3 is a top isometric view of the cutting system of FIG. 1 with thesurface layer loaded onto the table.

FIG. 4 is a front view of the cutting system of FIG. 3.

FIG. 5 is a view of a portion of the surface of FIG. 3.

FIG. 6 is close up view of FIG. 3 generally taken along area 6-6.

FIG. 7 is a cross-sectional view taken generally along lines 7-7 of FIG.6.

FIG. 8 is cross-sectional view taken generally along lines 8-8 of FIG.6.

FIG. 9 is cross-sectional view taken generally along lines 9-9 of FIG.8.

FIG. 10 is an isometric view of a surface material.

FIG. 11 is an isometric partial view of the surface material of withSCORES extending across the surface material.

FIG. 12 is a cross sectional view of the surface material takengenerally along lines 12-12 of FIG. 10.

FIG. 13A is a surface material loading station in one embodiment.

FIG. 13B is a surface material loading station in a second embodiment.

FIG. 14 is a top isometric view of a cutting system with the surfacematerial positioned on the conveyor material with a graphic materialpositioned on the surface material.

FIG. 15 is a top isometric view of a cutting system with a laser cuttingbelt on top of a first cutting belt.

FIG. 16 is a partial cutaway view of the laser cutting belt and firstcutting belt.

FIG. 17 is a cross sectional view of the laser cutting belt and firstcutting belt taken generally along lines 17-17 of FIG. 16.

FIG. 18A is an exploded view of the laser cutting belt prior to assembly

FIG. 18B is a side view of the laser cutting belt layers prior to theapplication of heat and pressure.

FIG. 18C is a side view of the laser cutting belt after the applicationof heat and pressure.

FIG. 18D is a side view of the laser cutting belt after holes arepunched therethrough.

FIG. 19 is a schematic view of the laser cutting belt being bent at anangle having a radius.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIG. 1 a cutting system 110 includes a cutting table 112and a cutting surface transfer station 114. Cutting table 112 includes afirst cutting material 116 and a first conveyor system 118. Cuttingtable 112 further includes a cutter system 120 including a pair of siderails 122, 124 and a horizontal rail 126 supporting a cutter 128. Cutter128 includes a cutting head 130 that may include one cutting tools suchas a blade, a router, or other similar cutting tools known in the art.Cutting head 130 may also include a sensor 132 such as an opticaldetector including but not limited to a CCD camera known in the art toassist in locating a sheet 134 to be cut. In one embodiment a vacuumsystem is provided to draw air through the top surface of the firstcutting material 116 into the table to assist in maintaining a sheet 134positioned relative to a portion of the surface of the first cuttingmaterial 116. Where sheet 134 is a sheet that will be cut by cuttinghead 130.

First cutting material 116 may be formed from a self-healing materialsuch as felt with or without appropriate backing material. Otherself-healing materials known in the art may also be used. First cuttingmaterial 116 in one embodiment extends over a top portion of cuttingtable 112 extending over a first or front roller, under a portion of thecutting table 112 and over a second rear roller. In this manner, cuttingsurface forms a continuous surface that may be moved about the table ina continuous manner. This continuous feature allows very long rolls orsheets longer than the cutting machine of materials 134 to be moved foreand aft relative to cutting table 112 and then moved from a frontportion 138 toward a rear portion 140 and then off to a storing locationthat is off of cutting table 112 in a vector direction from frontportion 138 toward rear portion 140. Cutting material 116 is moved alongthe y axis by a first and second roller positioned proximate the front138 and rear 140 respectively of cutting table 112.

Cutting table 112 includes an aluminum honeycomb support surface withholes through which a vacuum system is acts. When the vacuum system isoperating a vacuum is created within cutting table 112 that acts throughthe cutting material 116 upon the sheet material that is resting on anexposed surface of the cutting material to inhibit the sheet from movingrelative to the cutting material 116. In a traditional setup cuttingsystem includes a plurality of legs that rest upon a floor or supportand act to maintain cutting table above the floor. The floor ispositioned below the vacuum surface. The term “below” as used herein todescribe a relative position such that below is in the direction ofgravity and up is opposite the direction of gravity.

Cutting material 116 has an exposed surface 242 and an opposingunexposed surface. In one embodiment cutting material 116 forms acontinuous belt where a portion of the exposed surface faces in adirection away from table 112 and the opposing surface faces toward thetable 112. Cutting material 116 forms a continuous belt so as cuttingmaterial 116 is moved about the table the exposed surface will face awayfrom the direction of gravity and when the portion of the cuttingmaterial 116 moves about the first roller and the exposed surface willface toward the direction of gravity when the portion of cuttingmaterial is located below table 112.

First cutting material 116 may be a self-healing material which as usedherein is any material which is designed to endure repeated impacts froma mechanical blade without serious functional deterioration. By way ofexample a blade supported by cutting head is made to cut through a sheetsupported by first cutting material 116 and extend into first cuttingmaterial 116. Material 116 is formulated from a material such that a cutinto the first cutting material 116 allows continued use of the firstcutting material 116 for subsequent operations where a blade cutsadditional sheets being supported by first cutting material 116. Sheetsmay be paper, cardboard, cloth, plastic or other material typically usedin advertising but may be used in other applications as well. Firstcutting material 116 is often referred to as a gray belt in the machinecutting business. A workpiece supporting surface is described in U.S.Pat. No. 5,141,212 as being a foam sheet formed of “reticulated opencell polyurethane foam” and “where the foam is charcoal grey in color.”A cutting material support is also described in U.S. Pat. No. 6,945,645as including but not limited to elastomers and plastics, self-healingmat material, neoprene, rubber and polyurethane.

Cutting head 128 may also include a laser cutter directing the output ofa high-power laser, by computer, at the sheet 134 of material to be cut.Portions of sheet 134 are then either melts, burns, vaporizes away, oris blown away by a jet of gas leaving an edge with a high-qualitysurface finish. Since a laser operates at an elevated temperature,self-healing cutting surfaces 116 known in the art may also be melted,burned or vaporized away. In one embodiment a second cutting material142 having a higher melting and burning temperature point may be usedwith cutting table 112. The movement of a cutting head relative to acutting material is well known in the art. Cutting head 130 may be movedin an x-y direction by movement of cutting head along horizontal railand by moving the horizontal rail along the vertical rails. It is alsopossible to include other controls to provide an angular tilt from the zaxis so the cutting tool cuts sheet 134 at an angle other thanperpendicular to the plane defined by the top surface 136 of sheet 134.Cutting head 130 may also move in an up/down direction along the z axisto move a cutter toward and away from first and or second cuttingmaterial 116, 142.

Referring to FIG. 2, second cutting material 142 is loaded onto cuttingtable 112 from transfer station 114. In one embodiment second cuttingmaterial 142 is formed from a plurality of metal slats 144 movableconnected to one another with a connector 146. Referring to FIG. 6connector 146 is a flexible ribbon that is connected to each slat 144with a rivet 155, through an opening 153, or other connector known inthe art to operatively secure each slat 144 together to form the secondcutting material 142. In one embodiment metal slats 144 are formed froman aluminum material or aluminum alloy or other material having amelting and burning temperature above that of the heat transfer from thelaser cutter to the surface second cutting material 142. In oneembodiment, cutting table 112 includes a second drive system having adrive belt 148 having a plurality of pins 150 extending therefrom. Eachpin 150 being removably received in a corresponding aperture 152 of aslat 144. In one embodiment, drive belt 148 includes a plurality of apair of pins 150 with each pair of pins 150 being received in acorresponding pair of apertures 152. A drive wheel 154 is driven by amotor (not shown) in a clockwise and counterclockwise moving drive beltin fore and aft direction. In one embodiment, a second drive belt ispositioned parallel and spaced form first drive belt 148 includes aplurality of pins 150 that engages corresponding apertures 152positioned on each slat 144 remotely from the apertures 152 that engagewith pins 150 operatively connected with first drive belt 148.

Referring to FIG. 2, transfer load station 114 is positioned relative tocutting table 114 and each slat is secured to the first and second drivebelts by positioning the apertures 152 over the corresponding pints 150.Once the first slat 144 or first few slats 144 are secured to the firstand second drive belts, the drive belts maybe driven in a directiontoward rear 140 thereby transferring all of slats 144 onto cutting table112. In one embodiment, pins 150 provide a tight fit with apertures 152thereby allowing slats 144 to remain connected to pins 150 and the drivebelts as slats 144 are moved about a rear roller proximate rear portion140 and under cutting table 112. In this manner once all of slats 144are transferred to cutting table 112, slats 144 make a continuouscutting surface that extends over an upper surface of cutting table 112around the rear portion 140 under a lower surface of cutting table 112and around front portion 138. Once all of the slats 144 have beentransferred to cutting table 112, transfer station 114 may be moved awayon roller wheels 164. In one embodiment belts 148 may be formed from amaterial such as para-aramid synthetic fiber sold under the trademarkKevlar. Slats 144 may be removed from cutting table 112 and transferredto transfer station 114 in a reverse manner. Pins 150 are removed from afirst slat or leading edge slat and positioned within transfer station114, drive belts 148 are moved in a direction such that the slats aremoved from the belts 148 into transfer station 114.

Referring to FIG. 5 each slat 144 includes a first longitudinal edge 158and a second longitudinal edge 160 spaced from and generally parallel tofirst longitudinal edge 158. In one embodiment not shown longitudinaledges 158, 160 may be beveled such that when slats 144 are in the flatparallel orientation a portion of edge 158 is below the correspondingedge 160 of an adjacent slat. In this manner the laser is fully blockedfrom a laser beam extending between adjacent slats 144. Of course otheredge geometry that provides a continuous slat surface such that a lasertargeted perpendicular to an upper surface 162 of slat 144 would not beable to pass through a region between adjacent slats 144.

In one embodiment first cutting material 116 moves along with secondcutting material 142. In another embodiment second cutting material 142may be moved independently of the first cutting material 116.

While second cutting surface has been described as aluminum slats, othertypes of materials are also contemplated including but not limited to ametal mesh, a para-aramid synthetic fiber such as that sold by Kevlarand having a melting and burning temperature above a correspondingtemperature of the laser that may be used for cutting purposes.Additionally it is contemplated that the first cutting surface include aportion that is formed from a high heat resistant material andpositioned either to one side (x-axis) of cutting table 114 such that alaser may be used for cutting on one side while a traditional blade maybe used on a self-healing type of material such as felt may be on asecond side (x-axis) of cutting table 114.

Referring to FIG. 10 in another embodiment a second cutting material 170referred to herein as the laser cutting belt or laser belt includesaluminum foil 174. In one embodiment the aluminum foil 174 is between 1mil (0.001 in) and 10 mil thick (0.010 in). In one embodiment thealuminum foil is 5 mil thick. In one embodiment the aluminum foil layeris between 4 mil and 5 mil thick. In other embodiments the aluminum foilhas a thickness less than 1 mil and in another embodiment the aluminumhas a thickness that is greater than 10 mil thick. In one embodiment thealuminum foil is greater than 1 mil thick. In one embodiment thealuminum foil 174 is mounted, adhered or laminated to a carrier material176. In one embodiment the carrier material 176 is one of polyurethane,fiberglass, or other similar materials. The carrier material in oneembodiment is between 1-3 mm thick. In one embodiment a 1 mil-10 milaluminum foil is sufficient to scatter the laser beam and serves asgreat cutting underlay when cutting fabrics. In one embodiment thealuminum foil may be pure aluminum or an alloy containing other metals.

In one embodiment the aluminum foil 174 will be perforated with aplurality of apertures 180 to allow air flow to hold the graphic 134substrate in place relative to the second cutting material 170 as wellas to remove fumes that are created from the cutting process. A vacuumsupplied to the underside of the first cutting material 116 draws airthrough the aluminum foil 174. In an embodiment in which aluminum foil174 is secured to a carrier material 176, the vacuum will draw airthrough the apertures in aluminum foil 174 through the carrier material176 and through the first cutting material 116.

Referring to FIG. 12 each aperture 180 is formed by punching a disk 182from aluminum foil 174. Disk 182 is pushed a distance from the topsurface 184 of aluminum foil 174 toward a bottom surface 186 of carriermaterial 176. As a result a gap 188 is created between aluminum foil 174and disk 182. Disk 182 has an upper surface that is not co-planar withthe top surface 184 of aluminum foil 174 when the disk 182 is pushedinto the carrier material 176. The arrows in FIG. 12 illustrate thedirection of air flow. This air flow caused by the vacuum that draws airfrom the top region above the top surface 184 downwardly toward bottomsurface 186. This vacuum allows a graphic sheet 134 to be cut to be heldagainst the top surface 184 of aluminum foil 174. In one embodimentfirst cutting material 116 may be moved by conveyor system. The secondcutting material is then moved along with the first cutting material 116and in turn graphic material 134 is moved with the first cuttingmaterial and second cutting material as well.

In one embodiment second cutting material has a thickness of 1.8 mmmeasured along a vector direction from top surface 184 perpendicularlydownward to ward bottom surface 186. In one embodiment disk 182 ispositioned half way between upper surface 184 and bottom surface 186. Inone embodiment the location of disk 182 is more than or less than 50% ofthe distance between upper surface 184 and bottom surface 186. Thelocation of disk 182 must provide a sufficient annular opening 188 sothat the vacuum can adequately retain graphic sheet 134 against theupper surface 184 during the cutting operation and/or during movement ofthe second cutting surface about the rollers in the y vector directionas illustrated in FIG. 14.

The combined carrier layer 186 and aluminum foil layer 174 issufficiently flexible, that they can rolled around the rollers at eachend of the cutting machine and act as a conveyer system to transport thefabric thru the system. The combined carrier layer 186 and aluminum foillayer 174 is placed on top of the first cutting surface or primary belbelt which is used for knife cutting. When the operator wishes to switchfrom laser cutting, he/she will simply remove the combinedcarrier/aluminum foil and now the primary belt is used for bladecutting. While aluminum is identified as the foil material othermaterials may also be used. Note that the aluminum foil may have otherthicknesses than indicated herein. Also the substrate may be othermaterials such as but not limited to fiberglass.

Aluminum foil layer 174 is bonded to carrier layer 176 through at leastone of pressure and heat. The application of pressure and/or heatcreates a bond layer 178 between the carrier layer 176 and aluminum foillayer 174. The carrier layer may be treated with an adhesiveintermediate the carrier layer and the aluminum foil layer, or thecarrier layer may be formed of a material that bonds to the aluminumfoil layer with the application of pressure and/or heat. For example inone embodiment the carrier layer includes a polyurethane material thatmelts under the application of pressure and/or heat and bonds to thealuminum foil. Such a bonding process results in a bonded material thatdoes not significantly wrinkle as the composite carrier material andbonded aluminum foil is rolled about the system. The term wrinkle asused herein means a permanent crease or other raised or lowered ridge onthe surface of the aluminum foil that is caused by movement of thealuminum foil in the cutting system 110 and/or movement to and from thestorage module 114. It is believed that wrinkles are caused by differentradius of top surface and lower belt surface onto rollers causing acompression of the aluminum layer when the belt comes off the rollers.Wrinkles may lead to cracks in the aluminum and delamination of thealuminum from the carrier. Cracks and or delamination may lead to thelaser penetrating the aluminum layer and burning the carrier or eventhen first belt.

In one embodiment apertures 180 are formed by a punch having a crosssection between 50 mil and 150 mil forming aluminum foil disks 182. Thepunch separates the disk 182 from the aluminum foil 174 and moves thedisk toward the bottom surface 186 of the carrier material 176/Disks 182are clipped off evenly by the punch tool, then pressed flat halfway intothe carrier material 176 belt without too much of the carrier materialprotruding on the bottom surface 186 of the carrier material. Statedanother way, the movement of disk 182 into carrier material 176 maycause the bottom surface 186 under disk 182 to protrude away from thebottom surface 186 of carrier material casing a dimpled effect. In oneembodiment the protrusion of material is between 20 mil and 30 mil. Itis noted that the location of disk 182 downwardly into carrier material176 is greater than the distance of the protrusion as some of thecarrier material 176 is compressed.

To allow sufficient airflow caused by the vacuum the closeness ordensity pattern of the holes 180 created by disks 182 can be highbetween 25%-45% of the surface area of the aluminum foil 174. The openareas 180 defined by holes 180 help to make the final construction ofthe belt more flexible when passing by conveyer rollers. The cumulativearea defined by all holes 180 is referred to as the open area of thealuminum foil 174. In one embodiment the open area defined as a percentof the total area of aluminum foil 175 is between 25% and 45%. Of courseit is contemplated that the percent area of openings 180 to the entiresurface area of the aluminum foil 174 may be less than 25% or greaterthan 45%.

In one embodiment the punch sizes may be 60 mil, 94 mil, and 150 mil tocreate openings of varying diameter. In one embodiment disks are 182 arecircular creating an annular opening 188. However other noncircular diskshapes are contemplated as well.

In one embodiment, aperture 180 extends clear through aluminum foil 174and carrier material 176 such that disks 182 are completely removed fromsecond cutting material 170. Maintaining disks 182 within carriermaterial 176 allow for a greater surface area of aluminum when a laserfrom above is being used to cut a graphic material 134. If disks 182 areremoved completely, there is the possibility that a laser may travelthrough aperture 180 to the first cutting material 116 and would burn asa result. Disks 182 remaining in carrier material 176 allows for greaterhole size providing more flexibility in the first cutting material 170and providing for enhanced air flow for securing graphic sheet 134 tosecond cutting material 170 by the vacuum during the cutting process.The energy of the laser used to cut graphic sheets is known in the art.The second cutting material 170 has the material characteristic that thelaser when impinging on the second cutting material 170 after cuttingthrough the graphic sheet will not melt or burn the second cuttingmaterial 170. Stated another way the melting temperature and the burningtemperature of the second cutting material 170 including the aluminumfoil 172 and disks is such that the surface of the aluminum foil 172 anddisks 182 will not burn when the laser is cutting through a graphicsheet as is known in the art. In one embodiment the graphic sheets arethe type that are used for in-store displays and/or posters. Graphicsheets may be paper, Styrofoam, cardboard, plastic or other types ofdisplay material.

Referring to FIGS. 14 and 15 in one embodiment the belt is formed from abase substrate of fiberglass and includes a first layer of aluminum foilbonded to the substrate of fiberglass. The first layer of aluminum foilis bonded to the fiberglass with an adhesive. In another embodiment asecond layer of aluminum foil is bonded to the first layer of aluminumwith an adhesive material. In this embodiment the belt is formed of abase substrate formed of fiberglass, a first layer of aluminum bonded tothe fiberglass and a second layer of aluminum foil bonded to the firstlayer of aluminum with an adhesive.

Referring to FIGS. 14 and 15, the belt may include score lines orcreases that run perpendicular to the movement of the belt. The scoringof the aluminum layer or layers allows the belt to be rotated about therollers while minimizing or eliminating creasing of the aluminum foillayer on the belt as the belt is moved over the rollers from a firstorientation on top of the table to a second orientation under the table.

In one embodiment the aluminum foil 174 is another metal material. Inone embodiment the foil 174 is embossed with a pattern. The pattern maybe the pattern of the carrier material substrate as the aluminum foil ispressed onto the carrier material. Alternatively a pattern may beembossed onto the aluminum foil itself. It is believed that the embossedpatter assists in scattering the laser energy.

The top aluminum foil layer assists in scattering laser energy appliedto the belt to minimize or eliminate burn thru or residues left on thefabric being cut by the cutting machine by the laser. The fabric beingreferred to is the fabric that is on top of the belt and being cut bythe laser.

In one embodiment, the base layer of fiberglass is woven providingflexure stretch and compression properties so it conveys and rolls uponto the storage module 114 when not in use without causing wrinkles ordents in the top aluminum foil.

Referring to FIG. 13A storage module 114 is a bin 190 from which secondcutting material 170 may be stored in an accordion fashion. Referring toFIG. 13B in one embodiment storage module 114 is a roller system inwhich second cutting material may be stored on a roller. Roller system192 may include motors to wind and unwind secondary cutting material 170between storage module 114 and cutting table 112.

In one embodiment the aluminum layer is applied to the base layer from aroll having sufficient length to provide the entire length of thecutting surface. In another embodiment the aluminum layer is formed froma plurality of sheets that are secured to one another along theiradjacent peripheries to form the entire length and width of the cuttingsurface.

The carrier material may be formed of a material having a high frictionto the first cutting material conveyer belt which makes indexing andconveying more precise and reliable.

In one embodiment the apertures 180 are between 1 mm and 3 mm indiameter and are drilled or punched, spaced 25 mm apart in both X and Ydirection, thru the aluminum layer(s). The open, woven, carrier materialallows the vacuum flow thru it. The vacuum serves to hold the graphicsheet 134 to be cut in position while cutting is taking place by alaser.

Referring to FIG. 11 in one embodiment, creasing or scoring lines areadded in the Y (and potentially X) direction to make the belt morebendable and avoid wrinkles, dents, from the conveying process. Scoringof the surface of the belt may be added to make the aluminum surfacemore uneven, scattering the laser energy further. An uneven, texturedsurface, can also be achieved during lamination of the aluminum foil tothe woven fiberglass which structure will show thru using highlamination pressure.

When a user switches to blade cutting, the user removes thealuminum/fiberglass belt onto a roll-up device and the primary bladecutting belt is now exposed and ready for use. In one embodiment thelaser belt is relatively light weight so one operator can remove it (orput it back on) with relative ease using the roll-up/off rack.

In one embodiment the base carrier material that the aluminum foil isadhered to is a Habasit Conveyor Product under the number CM100FBS andin one embodiment the base material the base belt material that thealuminum foil is adhered to includes a cotton fabric having a nonwovenstructure that may include a polyester scrim on the traction belt side.In one embodiment a 5 mil aluminum foil is adhered to the base materialsuch as the Habasit material having a thickness of 65 mil with a 5 mildouble sided adhesive tape. In one embodiment a user applies a 6 ft.×4ft tape such as a tape sold by Tesa or other double sided pressuresensitive adhesive made by 3M or other companies to stick the secondcutting material to a first cutting material such as a standard grayconveyer belt known in the art that serves as the cutting surface whenthe second cutting material is not in use. Stated another way the secondcutting material may be employed only when a laser is going to be usedto cut a graphic material. Second cutting material having a metal foiland a carrier material may be referred to as the metal laminated laserbelt or aluminum clad belt.

Second cutting material 170 has two distal ends. The two distal ends areremovably connected together to provide a continuous belt about thecutting table 112. The two distal ends may be connected with a loop andfastener connector or other connectors known in the conveyor belt art.

A cutting machine includes a standard first cutting material or conveyorbelt to which the aluminum clad belt is secured to and/or over.Accordingly, depending on the application the aluminum clad laser beltis left on the cutting machine conveyor belt or it is removed and storedon a storage module

In one embodiment the base material to which the aluminum foil issecured has sufficient porosity to allow a vacuum to extend therethrough. A plurality of holes are punched through the aluminum foilwhile secured to the base material. In one embodiment holes are punchedin a row every 1 inch. In another embodiment holes are punched in a rowevery ½ inch.

In one embodiment the aluminum foil is 4 mil thick, and the carriermaterial is 125 mil thick. The apertures 180 each have a diameter ofbetween 100 mil and 125 mil. There are enough apertures in the aluminumfoil to provide between 25% and 25% open area. In one embodiment the topsurface of disk 182 is positioned between intermediate the top surfaceof the aluminum foil and the bottom surface of the carrier material. Inone embodiment disk 182 has a planar shape and in another embodimentdisk 182 may have a non-planar shape such as cone or other arcuateshape. The annular opening created by the disk and the opening 180 ofthe apertures provide sufficient volume to allow the vacuum to hold thegraphic sheet to the aluminum foil during the laser cutting operationand/or provide sufficient volume to provide efficient evacuation ofvapors created during the laser cutting operation.

In one embodiment, the carrier includes a non-woven belt including anupper portion and a lower portion having a scrim mesh there betweenbeing secured with a polyurethane filler. In one embodiment at leastpart of the non-woven belt includes cotton. In one embodiment thenon-woven belt includes primarily cotton fibers in combination with apolyurethane filler and/or scrim. An adhesive film is applied to analuminum film forming a laminated aluminum. In one embodiment theadhesive is a thermal plastic polyurethane (TPU) film that is applied toan aluminum sheet between 4-6 mil in a lamination process. In oneembodiment the aluminum sheet is 5 mil. The TPU film and aluminum filmlaminate may be rolled and then applied to the carrier material withheat and pressure to bond the aluminum/TPU laminated layer to thecarrier. In one implementation the carrier material includes a pluralityof divots or dimples covering its outer surface where the divot isconcave extending from one surface toward the other surface. Thelamination of the aluminum and TPU laminate to the carrier belt resultsin similar divot or dimple pattern on the aluminum outer surface. Seethe attached photograph/figures as an example.

When the laminated carrier belt, TPU and aluminum belt is rolled over a6 inch diameter conveyor belt roller the aluminum layer does not wrinkleor crimp or delaminate. The composite belt is then perforated from theback side. A plurality of perforations are made through the carrier, TPUand aluminum laminate from the back side adjacent the carrier material.Stated another way a punch enters the carrier material first andsubsequently exits the aluminum laminate. In this way the aperturesthrough the carrier material remains sufficiently open to allow air topass there through in a greater volume than if the perforations weremade through the aluminum layer first and the carrier materialssubsequently. In one implementation the aperture punch is 1.2 mm withopen area of 2.5%. Stated another way the 1.2 diameter holes are spreadacross the surface of the aluminum taking up 2.5% of the area and thenon punched regions makes up the remaining 97.5% of the surface area.The air permeates through the bottom surface of the cotton mate so thatthe perforations in the belt to not need to be aligned with the vacuumholes in the vacuum table.

In one embodiment, an adhesive layer such as a thermoplastic urethane orthermoplastic polyurethane (TPU) is laminated to an aluminum foilbetween 4 mil thick and 6 mil thick. The TPU may be in the form of afilm 1 mil thick. In one implementation the adhesive layer is sold underthe tradename DUREFLEX® PS8000 and may be 1 mil or may be greater than 1mil or may be less than 1 mil. Similarly, the aluminum foil may have athickness less than 4 mil or greater than 6 mil thick. Where one mil isone thousandth of an inch. The laminated TPU film and aluminum foil isthen laminated together with heat and pressure to a carrier/belt. In oneembodiment the carrier belt is sold under the tradename Cottonmate® byHabasit. In one embodiment the Cottonmate® belt is identified by Habasitas CM100FBS and item number H250000350.

During the lamination process the TPU flows at least partially into thefibers of the carrier belt which also includes a polyurethane filler.The result is that the final laminate provides sufficient rigidity andflexibility for the belt, TPU and Aluminum foil to be wrapped around aroller without wrinkling of the aluminum foil. A wrinkle as used hereincludes any permanent folding of the aluminum layer creating apermanent line, ridge or depression other than a dimple or convexdepression caused by the aluminum matching the general contour of thebelt material.

Once the belt, TPU and aluminum foil is completed the three layerlaminated materials is punched creating a plurality of 1.2 mm holesextending through the bottom of the belt through the top surface of thealuminum foil. In one embodiment the punch includes a free end whichfirst enters the bottom surface of the belt and subsequently extendsthrough the aluminum foil such that the free end of the punch extendsthrough the exposed upper surface of the aluminum foil. The rate of airflow through the aluminum foil and belt when placed on a vacuum tablewhen the holes are crated with the punch entering the belt first isgreater than the rate of air flow through the aluminum foil and bel whenthe holes are crated with the punch entering the aluminum foil first andthen entering the belt material. It is believed that the fibers in thebelt materials are preferably aligned when the punch enters the bottomexposed surface of the belt first and then subsequently enters thealuminum foil. This preferred alignment of the fibers provides for anincreased flow of air. When a laser is used to cut a product on thealuminum foil, TPU and belt laminated material as outlined above, thelaser does not extend through the holes or extend through the holessufficiently to burn any underlying belt or material that is supportingthe aluminum, foil, TPU and belt material.

The perforated carrier, TPU and aluminum laminated material is cut intorolls of 130 in wide belts. ALU tape is used for of laminated rollportions on a top side of the laminated materials and a Tesa tape isused on the opposite side. Whole belt is then cut into perfect rectangle(squared) and put on machine (typical size is 30 ft long×130 in wide).The laminated carrier, TPU and aluminum layers define a laser belt thatsupports a material that is to be cut by a laser. The laser belt can runon a standard gray cutting belt. However, the laser belt can also runwithout the gray belt if a user customer only does laser cutting and noblade cutting. The laser belt can be removed from the cutting equipmenton to a storage roller allowing the cutting equipment to be used with ablade/router cutting elements.

The cutting table may be used for non-laser operations by removing thesecond laser belt and using the first cutting material as the conveyorand cutting surface for traditional non-laser cutting operations inwhich a non-metallic material may be used.

Referring to FIG. 15 cutting system 110 includes a laser cutting belt170 formed from a plurality of panels 200 that form a continuous laserbelt. Each panel 200 is connected to an adjacent panel with a lacingconnection 202. Panels 200 have a common length as measured along thex-axis identified in FIG. 15. In one embodiment panels 200 have a commonwidth as measured along the y-axis. The length of panels 200 is measuredalong an edge 204 while the width of panels 200 is measured along anedge 206. In one embodiment multiple panels 200 cover the top surface oftable 112. A connection strip 208 secures two adjacent panels 200together to form a belt that extends over top surface of table 112 overa first roller under the table 112 and over a second roller. Theconnection strip 208 may be fabricated to ensure that laser belt 170fits a particular cutting machine geometry 110. The width of edge 214 ofconnection strip 208 may be varied while the layers that form strip 208are the same as panels 200 as described herein. Individual panels 200can be replaced if one is damaged or if the belt needs to be a differentlength. The modular panel assembly makes it fast and easy to build beltsin different lengths. Panels may be stored in a flat planar orientationuntil a belt needs to be assembled after which the belt may be stored onroller.

Referring to FIG. 15 a first cutting belt 116 extends over table 112.Table 112 includes a top portion having a fixed aluminum honeycombsurface with vacuum holes. The first cutting belt rides over this fixedsurface. A vacuum is applied to the top portion pulling air through thefirst cutting belt into the vacuum holes in the top portion.

In one embodiment roller 212 is driven by a motor and roller 210 is anidler roller that freely rotates about its longitudinal axis. Theposition of first cutting belt 116 is moved about the y-axis by rotationof roller 212. Laser Belt 170 is positioned on the first cutting beltand driven by movement of the first cutting belt.

Referring to FIG. 16 lacing 202 includes a first portion 216 that issecured to a first longitudinal edge of each panel 200 and a secondportion 218 that is secured to a second longitudinal edge of each panel200 where the second longitudinal edge is spaced rom and parallel to thefirst longitudinal edge of each respective panel. First portion 216 andsecond portion 218 are similarly secured to a first longitudinal edgeand second longitudinal edge of connecting strip 208. A connecting rod220 is removably received in a plurality of openings 222 and openings224 in respective first portion 216 and second portion 218. In thismanner adjacent panels 200 are secured to one another. Note that firstportion 216 and second portion 218 are able to pivot about connectingrod 220 as the laser belt rotates about rollers 212 and 210. The gapsbetween the various components of first portion 216 and second portion218 as viewed from the z-axis are between 0.5 mm and 1 mm. Thisminimizes the space for the laser beam to get thru and cut into thefirst cutting material or grey below the laser belt.

Referring to FIG. 16-FIG. 18D each panel 200 and 208 include a baselayer 226 having a center portion that is woven covered by a top and abottom portion of nonwoven material. An intermediate layer 228 ofthermoplastic polyurethane (TPU) is applied to a top layer of the baselayer 226. A top layer of aluminum foil having a thickness between 4 milto 6 mil thick is secured to the base layer by the TPU intermediatelayer with the application of force and heat. The TPU layer 228 meltsunder the force and heat and operatively bonds the aluminum layer 230 tothe base layer 226.

Referring to FIG. 16 a schematic illustration of panel 200 not drawn toscale illustrates that base layer 226 as a result of its woven centerlayer has a pattern that creates dimples or depressions 236 on thealuminum layer once the aluminum layer is secured to the base layer 226by the application of pressure and heat. In one embodiment dimples 236have a depth of 1 mm to 0.2 mm and a generally round shape at the uppermost portion of the dimple. The upper most portion of the dimple is thearea furthest from the base layer 226 in the z direction. It is believedthat the dimple pattern on the exposed surface of the aluminum layerhelps to dissipate the energy of the laser that may impact the exposedaluminum surface thereby minimizing any damage to the laser belt 170during a laser cutting operation.

Once the aluminum layer 230 is secured to the base layer 226 by the TPUlayer 228 a plurality of through holes are punched through panel 200. Inone embodiment the through holes have a diameter of 1.3 mm. As a resultthe area of each opening at the exposed surface of the aluminum layer ofthe panel 200 is 1.327 mm² (π(1.3 mm/2)²). The number of through holes238 on each panel is set such that the cumulative area of the opening ofall the through holes is 0.6% of the entire surface area of the panel200. In one embodiment the cumulative open area of the through holes isless than 1% of the entire surface area of the panel. In one embodimentthe cumulative open area of the through holes is less than 0.3% of theentire surface area of the panel. In one embodiment the cumulative openarea of the through holes is greater than 1%.

The diameter of the through holes and the frequency of the through holesare set to minimize any delamination of the aluminum layer from the baselayer while allowing sufficient opening that a vacuum applied throughfirst cutting material 116 will have sufficient force to hole a sheet tobe cut to the exposed surface of laser belt 170. In one embodimentthrough holes 238 are arranged in a grid along the x and y axis whereholes are positioned 15 mm apart on one of the x and y axis and off set7.5 mm on the other of the x and y axis.

Referring to FIG. 19 the allowable bending radius of each panel isgreater than 3 inches. State another way the exposed surface of thealuminum layer 230 will not wrinkle as each panel 200 travels about the6 inch diameter rollers 210 and 212. As discussed herein the termwrinkle as used herein means a permanent crease or other raised orlowered ridge on the surface of the aluminum foil that is caused bymovement of the panels 200 in the cutting system 110. Specificallymovement of each panel 200 about rollers 210 and 212 will result in thepermanent formation of a crease in the exposed surface of the aluminumlayer 230. In this manner laser belt 170 retains a surface free frompermanent linear lines that may impede the operation of the laser beltduring a laser cutting operation.

Referring to FIG. 17 a cross sectional view of the laser cutting belt isillustrated in that the upper surface of base layer 226 the TPU layer228 and Aluminum layer 230 all have a similar dimple geometry.

Referring to FIG. 18A base layer 226 has a portion that has a non-smoothpattern that is transferred to the initially smooth TPU and Aluminumlayers. FIG. 18A is schematic of base layer that in one embodiment has asmooth non-woven upper layer and lower layer. The dimpled pattern of theupper layer of the non-woven portion of the base layer is formed fromthe woven central portion of the base layer upon the application ofpressure to the aluminum layer. The base layer, TPU layer and Aluminumlayer are positioned on one anther is illustrated in FIG. 18B and afterthe application of pressure and heat panel 200 is formed with thealuminum layer being secured to the base layer by the TPU layer. In oneembodiment no adhesive is used to secure the base layer TPU layer andaluminum layers together. The resultant dimpled patter is illustrated inFIG. 18C.

Referring to FIG. 16 the geometric regions 232 are schematic of theregion formed by the woven central portion of the base layer. Thegeometric regions 234 and 236 represent the geometric dimples that areformed on the Aluminum and TPU layers of each panel 200 and panel 208.

Cutting system 110 may be used in a first mode in which only the firstcutting material or first cutting belt 116 is positioned on table 112.In this mode a blade is used to cut a sheet 134 on the exposed uppersurface of first cutting material belt or gray belt 116. In a secondmode of operation second cutting material or laser belt 170 is added tocutting system 110. Starting with a first panel 200 a second panel 200is attached thereto with lacing 202 by securing first portion 216 offirst panel 200 with second portion 218 of second panel 200 with a rod220. Subsequent panels 200 are added until laser belt 170 extendscompletely about table 112 such that the first panel and the last panelsecured to the laser belt 170 are positioned on the upper surface of thefirst cutting material. Stated another way the first panel 200 and thelast panel 200 secured to the chain of panels 200 are positioned onfirst cutting material such that the first panel 200 and last panel 200are positioned a distance above the floor or support of the legs of thecutting equipment greater than the distance of the first cuttingmaterial. When the distance between the first panel 200 and the lastpanel 200 secured to the belt is less than the width of the panels 200 aconnection panel 208 is formed to conform to the width between the firstpanel 200 and the last panel 200. The connection panel 208 is secured tothe first panel 200 by a connector 202.

In one embodiment laser belt 170 may be constructed on a separate worksurface and transferred to cutting equipment 110 by transfer equipment114 discussed herein above. Where the transfer of laser belt 170 ispositioned about first cutting material belt 116. In this manner it ispossible to use a blade to cut a sheet on cutting equipment 110 byplacing a sheet to be cut on first cutting material or gray belt 116 andthe using a laser to cut a sheet to be cut by adding the laser belt tothe cutting equipment 110. There is no need to remove the first cuttingmaterial or gray belt when the laser belt is added to the cuttingequipment. When a user desires to use a blade to cut a sheet an operatorwill remove the laser belt 170 by disconnecting one of the lacingconnectors 202 by removing a single rod 220 and removing the laser belt170 by using transfer equipment 114. It is not necessary to remove rods220 from each respective connector 220 in order to remove belt 170. Auser may wind laser belt 170 about a roller on a transfer equipment 114as illustrated in FIG. 13B for example. However other transfer equipmentknown in the art is also contemplated to remove and reattach laser belt170 from and to table 112.

Once laser belt 170 is secured to table 112 laser belt may be movedabout table 112 in the y direction by moving driven roller 212. In thismanner both the first cutting material or gray belt 116 and the laserbelt 170 are moved in unison. In one embodiment the friction between thebottom surface of laser belt 240 and the exposed surface 242 of firstmaterial or gray belt 116 is sufficient to move laser belt 170 withfirst material or laser belt 116.

Second cutting material 170 has a higher melting and burning temperaturepoint than the first cutting material 116. The aluminum layer of thesecond cutting material 170 does not burn or melt when exposed to thelaser that cuts a sheet positioned on exposed surface 244 of the laserbelt 170. Additionally, the diameter of the through holes 238 and theopen spaces in connector 202 are small enough as to minimize any damageto the first cutting material when the laser is operated to cut a sheetthat is positioned on the exposed surface 244 of the laser belt 170.

Graphic sheet or material 134 may be a single sheet of material having awidth and length along the x and y axis that are less than the width andlength of the table 112. However, the graphic sheet or material may be aroll of material where portions of material from the roll is placed ontothe first or second cutting material belts in a discrete fashion suchthat multiple graphic images are cut from the roll. For example aleading portion of a roll of material may be placed on the exposedsurface of the first cutting material or second cutting material and acutting knife or laser cuts a portion of the leading portion of theroll. The roll then may index along the y axis and a subsequent cuttingoperation may be conducted on a second portion of the roll to cut asecond graphic image from the roll. This may be repeated as graphicimages are cut all along the roll as portions of the roll on placed ontothe first or second cutting materials.

While laser belt 170 can be used in a dual belt mode in which laser belt170 is placed over the gray belt 116 it is also contemplated that laserbelt 170 may be used on a cutting machine independently of the gray belt116. Accordingly laser belt 170 as described herein may be driven alongthe y axis directly by a drive roller or by other drive means.

While the foregoing written description of the invention enables one ofordinary skill to make and use what is considered presently to be thebest mode thereof, those of ordinary skill will understand andappreciate the existence of variations, combinations, and equivalents ofthe specific embodiment, method, and examples herein.

What is claimed is:
 1. A cutting apparatus comprising: a cutting table;a first cutting material belt movably supported about the cutting table.a second cutting material belt removably supported above the firstcutting material belt, the second cutting material belt including ametal material having a plurality of apertures extending therethrough.2. The apparatus of claim 1, wherein the metal material is aluminumhaving a thickness greater than 1 mil.
 3. The apparatus of claim 2,wherein the aluminum is secured to a carrier layer formed of a nonmetalmaterial with a thermoplastic polyurethane material.
 4. The apparatus ofclaim 1, wherein the second cutting material belt is removablypositioned about the first cutting material.
 5. The apparatus of claim4, wherein the second cutting material belt includes a plurality ofstrips connected to one another with a mechanical connector.
 6. Theapparatus of claim 1 wherein the second cutting material belt extendsabout the first cutting material above and below the cutting table. 7.The apparatus of claim 1, wherein the apertures have a diameter between1 mm and 2 mm.
 8. The apparatus of claim 1, further including a vacuumsystem that draws air through the first cutting material belt and thesecond cutting material belt sufficient and to retain a graphic materialadjacent to the second cutting material belt.
 9. The apparatus of claim1, wherein the apertures include a plurality of apertures that make upless than 1% of the top surface area of the second cutting materialbelt.
 10. The apparatus of claim 1, further including a laser havingsufficient energy to cut a graphic material supported on the secondcutting material belt without burning and melting the laser cuttingmaterial belt.
 11. The apparatus of claim 1 further wherein the firstcutting material is a self-healing material.
 12. The apparatus of claim1 further including a cutting head having a laser.
 13. The apparatus ofclaim 1 further including a transfer station to wind and unwind thesecond cutting material belt about a storage roller.
 14. The apparatusof claim 1 further wherein the second material laser belt is formed froma plurality of panels that are mechanically connected together allowingadjacent panels to pivot along a longitudinal axis of the connector. 15.The apparatus of claim 14 wherein one of the plurality of panels may bereplaced.
 16. The apparatus of claim 1, including a drive roller and anidler roller, wherein the first cutting material belt and the secondcutting material belt are driven about the table by movement of thedrive roller.
 17. A process for adding a laser cutting material to acutting machine comprising: providing a first cutting material beltpositioned about a table; securing a laser cutting material belt aboutthe first cutting material belt; and applying a vacuum through the firstcutting material belt and second laser cutting material belt to secure afirst graph sheet to the laser cutting material belt.
 18. The process ofclaim 17, including cutting the first graphic with a laser.
 19. Theprocess of claim 18, including removing the laser cutting belt from thefirst cutting material belt.
 20. A cutting belt for a cutting machine,the cutting belt including: a plurality of panels; each panel includinga base layer and an aluminum layer secured to the base layer; and eachpanel being secured to an adjacent panel with a connector.